the secret of lean

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The Secret of Lean Shmuel Korb

Lean/Kanban Israel Meetup 11 February 2013


Results of Lean Implementation • Lead time: from 6 weeks to 1

day

• Productivity: +162%

• Gross Profit: from 38% to 51%

• Inventory turns: from 3 to 18

• Customer service: from 50% to 98%

• Sales: from $100 to $400 million

• EBITDA: from 6.2% to 20.8%

• Enterprise value: from $30 to $770 million (+2467%!)


Lean Alphabet Soup

• 5S

• TPS

• TWI

• OPF

• ZDQ

• VA/NVA

• TQM

• TPM

• Kanban

• Kata

• Gemba

• Genchi Gembutsu

• Hoshin Kanri

• A3

• 5Why

• QATS

• QFD

• 3P

• Jidoka

• Heijunka

• Takt

• Kaizen

• Kaikaku

• Yonkoten

• Kambawashi

• SMED

• JIT

• VSM

• PDCA

• Poke-Yoke


Lean Library


What is Lean?

Continuous

Improvement

Respect for

People


How do you make Lean work?

• The Secret…


The Secret

1. Teach your people to see the 7 wastes

2. Fix what bugs you

3. Document the improvements


See the Waste

http://www.youtube.com/watch?v=uyzMQ2WwmWo


All Processes are Made Up of

Activities

• Every Activity Either:

• Adds Value • To Customer

• Changes Something

• Is Waste


See the Waste in the Company

(No Matter How Small)

http://www.youtube.com/watch?v=-GOel4TlDGs


Types of Waste

• MUDA

• MURA

• MURI


MUDA

עיבוד עודף

/פגמים עובדה

חוזרת

שינוע

מלאי

המתנה

תנועה

ייצור עודף

http://wongwowai.files.wordpress.com/2008/09/the252072520wastes.jpg


Teach Everyone to See Waste

http://www.youtube.com/watch?v=QWEFy8cttR4


Fix What Bugs You

http://www.youtube.com/watch?v=Su_c2UhSRDw


Kaizen: Everyone, Everywhere,

Every Day

http://www.youtube.com/watch?v=3OEePS7Oh_g


Document the Improvements


Share the Improvements


Good Luck

• On your Lean Journey…

the secret of lean

Education